Installation instruction TENSOREX C+ TENSOREX C+ is a new spring automatic tensioning device for tramway, light and heavy railways Overhead Contact Lines ( OCL ). TENSOREX Products are only by PFISTERER Fixing bracket TYPE A for O and H poles Fixing bracket TYPE B for O and H poles Are available different fixing brackets, for special poles or walls. Also it s possible to install TENSOREX C+ horizontally. Please ask direct information to Pfisterer srl. Instruction code 000300303EN ed. 15-05-2012 Page 1
Installation tools Package checking Important information - 1 water level Verify that the package contains: - 1 Flat steel rod min 500mm long - Tensorex C+ (TRC+) or in alternative long water level Compensating length and pull force - 1 thermometer are correct - 1 of 2 pulling devices - Fixing bracket - 1 of 2 come-along clamp Fit to the pole - 1 Dynamometer (optional) - Installation instruction - Before to proceed, you have to know the length of the line between TENSOREX C+ and middle point - Installers must be good trained and to know how the device works 1.a) Fixing bracket type A Fix the bracket to the mast, to the line direction, at the height prescribed by the rail administrator, from the top of rail (G). In the fixing bracket there is a reference hole, circa in the middle, see photo 1.a. It must be level mounted. Round masts and beams have different fixing bracket, and they are supplied from Pfisterer in according to the customer requirements. 1.a 1.b 1.b) For Type B Fix both L profiles keeping the distance between the upper and lower L profile 500 mm, tolerance: -0 / +5 mm. The two holes ø26 must be vertically aligned. It s helpful to insert the rod M24 and check all parts by water level ( see photo 1.b ). height: H G 2 3 2.a) Hang TRC+ like photo 2, and lift up it by crane or hoist-tackle, out from the wood box (photo 3 and 4). In case, the hoist chain must be min 15 meters long. 4 2.b) Take out the two pins ø19 and fit TRC+ in the fixing bracket. Before the bottom fitting, then the upper one (photos 5 and 6). Look it by set pins upward and splits under. 5 6 7 Now TRC+ can be pulled. Before, please make sure that two stainless steel tension wires are in the pulley races down! Also wind them two times (photos 5,6 and 7) Instruction code 000300303EN ed. 15-05-2012 Page 2
3) Tie two belts to the front balance (photo 8) and acting by pulling device take the solid arrow on the 0-point of the scale ( photo 9 ). Now TRC+ is applying to the line approximately the nominal force. 8 9 Warning: we suggest to fit in advance to front balance all hardware you need ( insulators, turnbuckles,..), so to make easy to joint later TRC+ to OCL. 10 11 4) Acting on two nuts at the top (see red circles in photo 10) to align TRC+ to the OCL slope. Do it laying a flat steel rod circa 500mm long on flat side of the pulley. TRC+ is aligned when it s approximately in line with the tensioned wire, see photo 11. At the end, verify that the M14 rods are out equals lengths. 5) Now, TRC+ must be further set taking in account tension length and temperature. See photo 12. Example of TRC+ setting TRC+ type.450/xxxx kg Tension length 500 meters (1) Ambient Temperature...25 C (1) distance between TRC+ and middle point 12 Calculate the setting number crossing the above value in the table 1. In this case is 140mm Then pull TRC+ until the arrow reach the number ( see photo 12 ). It s recommended to mount a compensating element as turnbuckle between TRC+ and OCL. Joint TRC+ to OCL and release it. A fine-tuning is possible acting on compensating element. 6) Finally, activate the "stoppers", using a screwdriver to press on both sides of the device, photo 13. Instruction code 000300303EN ed. 15-05-2012 Page 3
6) Finally, activate the "stoppers", by a screwdriver to push on both sides of the device, photo 13. IMPORTANT NOTE Stoppers work preserving the functionality of the TRC+ in case of anomalous OCL contraction (very low temperature) or the device is out of setting. When stoppers are working, TRC+ becomes as a rigid body, so OCL becomes from compensated to fix end. 13 Tab 1 ( TRC+ Type 450/ kg and center temperature 15 C ) E.g. for the Netherlands/Germany is based on a nominal (center) temperature of 10 C, the radial black line on the scale diagram shows it as being half the maximum length variation to regulate. In the photo 12 is the type TRC+ is 450/... so this is 225 mm. Warning: setting table above is just an example. Always check the setting tab fixed on the top of Tensorex C+ or attached to this manual, ANNEX 1 TENSOREX C+ control after installation After a certain period from the installation, it s well to verify and eventually compensate the anomalous extensioncontraction of the contact wires pulled by TENSOREX C+. Do it following the same procedure as at step 5. Recover OCL by the pulling devices until the index of TENSOREX C+ is in the correct position, taking into account the ambient temperature during this operation (step 5, photo 12). The same procedure must be done even in case of other controls, in consequence to changes or replacement of fittings, middle point,. Instruction code 000300303EN ed. 15-05-2012 Page 4
In case of OCL collapse In case of OCL collapse consequent de-wirement, proceed as follows: a) Verify the stoppers (see step 6, photo 13). If they are deformed or broken mean that a load > 40KN has been applied to TRC+. In this case TRC+ must be substitute by another one. b) If, after de-wirement, the stoppers are not damaged and work properly (check free rotation) TENSOREX C+ can be used again. Before to set it again, make a visual inspection and control carefully the state of stainless steel cables. They must not present any bending section or single wire broken. If singles wires are broken, replace the ropes. For TRC+ setting, repeat step 4, 5 and 6 in the manual. Note PFISTERER srl via Sirtori,45/D 20017 Passirana di Rho (Mi) Italy www.pfisterer.it pfisterer@pfisterer.it Instruction code 000300303EN ed. 15-05-2012 Page 5